Energy storage device assembly

ABSTRACT

Embodiments of the present disclosure provide an energy storage device assembly, which may include: a plurality of energy storage devices, each energy storage device having a first electrode and a second electrode, the plurality of energy storage devices being connected to one another in series; and a liquid coolant transmission line in thermal communication with at least one of the plurality of energy storage devices.

This application is a continuation in-part of previous U.S. patentapplication Ser. No. 14/190,684, filed Feb. 26, 2014, which claimspriority to U.S. Provisional Patent Applications No. 61/769,937 filedFeb. 27, 2013, and 61/837,681 filed Jun. 20, 2013, all of which arehereby incorporated by reference.

BACKGROUND OF THE INVENTION

This disclosure relates generally to energy storage devices, and moreparticularly, to a modular assembly and cooling system for one or moreenergy storage devices, including capacitors, ultracapacitors, andbatteries.

In conventional capacitor assemblies, a plurality of capacitor cells,ultracapacitor cells, batteries, or other energy storage devices areloosely held together, through securing components, within a housingthat can subject the cells to a certain amount of external forces,including vibratory forces. In some cases, these forces can exceed thestrength of the securing components. In such cases, vibratory action candislodge, rotate, wear and/or destroy portions of the devices andconnections within and/or between them. This situation can reduce thedurability and lifespan of the energy storage devices.

Some energy storage devices, including those with capacitor assemblies,may use adhesive substances and thermal inserts between capacitor cells.These components can dissipate heat generated during operation andreduce rotation and dislodging of the capacitor cells within theassembly, but are typically placed between capacitors and may be locatedalong or nearby the path of an electric current. To connect energystorage devices together, complex bonding mechanisms between numeroussurfaces may be used. These design choices have proven to impair theperformance of energy storage devices, and can limit the opportunity tomake further modifications.

Some capacitor assemblies use bus bars with circular ends to connectcapacitor cells to one another. These bus bars can be designed to fullysurround each end of a capacitor cell or an electrode. These circularends must be precisely machined as close as possible to the shape of theend of the capacitor cell for the bus bars to properly contact andconnect with a device. This limitation can greatly increasemanufacturing time and/or produce an imprecise fit, leading to faultyand/or inconsistent performance.

In previous energy storage devices, such as traditional capacitor cells,a terminal is attached to an end of the cell through a radial weld orradial interference fit at an interface between the cell and theterminal. These points of attachment used complex geometries, with weldbonds located at several points of contact. Attachment points accordingto previous designs could cause difficulty or added complexity inmanufacturing processes. In addition, a radial weld or radialinterference fit can also cause attachment points between the cell andterminal to perform inefficiently or include imprecise geometricalconnections.

The passage of electrical currents through particular materials,including ultracapacitors, may cause certain materials in an assembly toexperience temperature increases.

BRIEF DESCRIPTION OF THE INVENTION

A first aspect of the present disclosure includes an energy storagedevice assembly comprising a plurality of energy storage devices, eachenergy storage device having a first projecting electrode and a secondprojecting electrode; and a weld directly bonding adjacent first andsecond projecting electrodes of adjacent energy storage devices to oneanother in series.

A second aspect of the present disclosure includes a bus bar comprising:a base; and a pair of opposing, arcuate ends coupled by the base, thepair of opposing, arcuate ends configured to engage and only partiallysurround two substantially circular projecting electrodes of twoadjacent energy storage devices.

Another aspect of the invention includes an apparatus for use in anenergy storage device assembly including a plurality of energy storagedevices, the apparatus comprising: a structural thermal bridge includingat least one thermal plate configured to engage an end of at least apair of the plurality of energy storage devices to physically secure theenergy storage devices and thermally communicate heat therefrom; and anelongated sleeve housing surrounding the plurality of energy storagedevices, and the structural thermal bridge further comprises: a firstthermal plate positioned between the elongated sleeve housing and afirst end of the at least a pair of the plurality of energy storagedevices, the first thermal plate including a plurality of recessesshaped to correspond to the first end of the at least a pair of theplurality of the energy storage devices; and a second thermal platepositioned between the elongated sleeve housing and a second end of atleast a pair of the plurality of energy storage devices, the secondthermal plate including a plurality of recesses shaped to correspond tothe second end of the at least a pair of the plurality of energy storagedevices.

A further aspect of the invention includes a housing for an energystorage device assembly comprising: an elongated sleeve having acontoured interior configured to enclose and contact each of a pluralityof energy storage devices and a mount configured to retain a circuitboard to the elongated sleeve housing.

An additional aspect of the invention includes an energy storage deviceassembly comprising: a plurality of energy storage devices, each energystorage device including a first projecting electrode and a secondprojecting electrode; and a weld bond electrically connecting respectivefirst and second projecting electrodes of adjacent energy storagedevices end-to-end.

Another aspect of the invention includes an energy storage deviceassembly comprising: a plurality of axially aligned energy storagedevices each having electrodes, immediately adjacent energy storagedevices being connected at a joint; an elongated sleeve housing having alength, the elongated sleeve housing enclosing the plurality of energystorage devices; a circuit board extending along the length of theelongated sleeve housing; and a plurality of substantially identicalwiring harnesses for coupling the circuit board to the plurality ofaxially aligned energy storage devices.

Yet another aspect of the present disclosure includes an energy storagedevice assembly, which can include: a plurality of energy storagedevices, each energy storage device having a first electrode and asecond electrode, the plurality of energy storage devices beingconnected to one another in series; and a liquid coolant transmissionline in thermal communication with at least one of the plurality ofenergy storage devices.

An additional aspect of the present disclosure includes a cooling systemfor an energy storage device assembly, the cooling system including: aplurality of liquid coolant transmission lines positioned within anelongated sleeve housing for enclosing a plurality of energy storagedevices therein, the plurality of liquid coolant transmission linesbeing configured to absorb heat from the plurality of energy storagedevices.

An aspect of the present disclosure includes an energy storage deviceassembly, which may include: a plurality of energy storage devices, eachenergy storage device having a first projecting electrode and a secondprojecting electrode; a weld directly bonding adjacent first and secondprojecting electrodes of adjacent energy storage devices to one anotherin series; and a liquid coolant transmission line in thermalcommunication with one of the plurality of energy storage devices, theliquid coolant transmission line extending substantially across thelength of at least two adjacent energy storage devices bonded to oneanother in series.

The illustrative aspects of the invention are designed to solve one ormore of the problems herein described and/or one or more other problemsnot discussed.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the disclosure will be more readilyunderstood from the following detailed description of the variousaspects of the invention taken in conjunction with the accompanyingdrawings that depict various aspects of the invention.

FIG. 1 shows an isometric view of an energy storage device assemblyaccording to embodiments of the invention.

FIG. 2 shows an exploded view of an energy storage device assemblyaccording to embodiments of the invention.

FIG. 3 shows a perspective view of several energy storage devicesaccording to embodiments of the invention.

FIG. 4 shows a side view of two energy storage devices connectedend-to-end according to embodiments of the invention.

FIG. 5 shows a perspective view of a laser welding process according toembodiments of the invention.

FIG. 6 shows a side view of energy storage devices with a thermal insertaccording to embodiments of the invention.

FIG. 7A shows a perspective view of a thermal insert according toembodiments of the invention.

FIG. 7B shows a perspective view of two sub-portions of a thermal insertaccording to embodiments of the invention.

FIG. 7C shows a perspective view of a thermal insert located on aprojecting electrode of an energy storage device, according to anembodiment of the invention.

FIG. 7D shows a perspective view of several energy storage devices in anassembly, with thermal inserts provided at joints between each energystorage device.

FIG. 8A shows a side view of energy storage devices with a thermalconducting layer according to embodiments of the invention.

FIG. 8B shows a cross-sectional view of energy storage devices with athermal conducting filler according to embodiments of the invention.

FIG. 9 shows a perspective view of an elongated sleeve housing accordingto embodiments of the invention.

FIG. 10 shows a perspective view of an elongated sleeve housing andcircuit board according to embodiments of the invention.

FIG. 11A shows a schematic view of a circuit board coupled to energystorage devices via a set of a single type of wiring harness accordingto embodiments of the invention.

FIG. 11B shows an alternate, perspective view of a circuit board coupledto energy storage devices using a single type of wiring harness with ahousing removed, according to an embodiment of the invention.

FIG. 12 shows a perspective view of a structural thermal bridge andenergy storage devices according to embodiments of the invention.

FIG. 13 shows a perspective view of a thermal plate, bus bar, andterminal according to embodiments of the invention.

FIG. 14 shows a thermal plate, and an energy storage device withconnected terminal according to embodiments of the invention.

FIG. 15 shows a perspective view of a terminal according to embodimentsof the invention.

FIG. 16 shows a perspective view of a terminal in position on an energystorage device according to embodiments of the invention.

FIG. 17 shows a perspective view of a terminal bonded to an energystorage device according to embodiments of the invention.

FIG. 18 shows a perspective view of a terminal passing through astructural thermal bridge according to embodiments of the invention.

FIG. 19 shows several bus bars and terminals connected to energy storagedevices according to embodiments of the invention.

FIG. 20 shows a perspective view of a bus bar according to embodimentsof the invention.

FIGS. 21-25 show perspective views of an energy storage device assemblywith a cooling system according to embodiments of the presentdisclosure.

FIGS. 26 and 27 show perspective views of a cooling system for use withan energy storage device assembly according to embodiments of thepresent disclosure.

It is noted that the drawings of the invention are not necessarily toscale. The drawings are intended to depict only typical aspects of theinvention, and therefore should not be considered as limiting the scopeof the invention. It is understood that elements similarly numberedbetween the figures may be substantially similar as described withreference to one another. Further, in embodiments shown and describedwith reference to FIGS. 1-27, like numbering may represent likeelements. Redundant explanation of these elements has been omitted forclarity. Finally, it is understood that the components of FIGS. 1-27 andtheir accompanying descriptions may be applied to any embodimentdescribed herein. The detailed description explains embodiments of theinvention, together with advantages and features, by way of example withreference to the drawings.

DETAILED DESCRIPTION OF THE INVENTION

In the following description, reference is made to the accompanyingdrawings that form a part thereof, and in which is shown by way ofillustration specific exemplary embodiments in which the presentteachings may be practiced. These embodiments are described insufficient detail to enable those skilled in the art to practice thepresent teachings and it is to be understood that other embodiments maybe used and that changes may be made without departing from the scope ofthe present teachings. The following description is, therefore, merelyillustrative.

When an element or layer is referred to as being “on,” “engaged to,”“disengaged from,” “connected to” or “coupled to” another element orlayer, it may be directly on, engaged, connected or coupled to the otherelement or layer, or intervening elements or layers may be present. Incontrast, when an element is referred to as being “directly on,”“directly engaged to,” “directly connected to,” or “directly coupled to”another element or layer, there may be no intervening elements or layerspresent. Other words used to describe the relationship between elementsshould be interpreted in a like fashion (e.g., “between” versus“directly between,” “adjacent” versus “directly adjacent,” etc.). Asused herein, the term “and/or” includes any and all combinations of oneor more of the associated listed items.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,”“lower,” “above,” “upper,” “inlet,” “outlet,” and the like, may be usedherein for ease of description to describe one element or feature'srelationship to another element(s) or feature(s) as illustrated in thefigures. Spatially relative terms may be intended to encompass differentorientations of the device in use or operation in addition to theorientation depicted in the figures. For example, if the device in thefigures is turned over, elements described as “below” or “beneath” otherelements or features would then be oriented “above” the other elementsor features. Thus, the example term “below” can encompass both anorientation of above and below. The device may be otherwise oriented(rotated 90 degrees or at other orientations) and the spatially relativedescriptors used herein interpreted accordingly.

The present disclosure generally relates to assemblies of energy storagedevices, including energy storage device assembly 10 depicted in FIGS. 1and 2. According to embodiments of the disclosure, assembly 10 canpermit several energy storage devices to be electrically connected toeach other in series, with a joint such as a weld bond joining anelectrode on an energy storage device with a successive energy storagedevice. As described in further detail herein, applying a weld bond toconnect several energy storage devices in a series arrangement can avoidthe use of components with higher resistances, such as conventional busbars. Thus, assembly 10 can allow more energy storage devices to bejoined by series connections, thereby providing a more effective energystorage apparatus that avoids the use of conventional bus bars.

Energy storage device assembly 10 can also be modular and thus scaled oraltered to interact with a plurality of energy storage devices (e.g.,sets of capacitors, sets of ultracapacitors, batteries, etc.), accordingto embodiments of the invention. For instance, energy storage deviceassembly 10 can be selected to contain a number of energy storagedevices that allows for assembly 10 to have a predetermined operationalvalue, including a predetermined voltage or capacitance. In otherembodiments, energy storage device assembly can have several rows, witheach row containing, for example, one, eight, ten, twenty, or anydesired number of energy storage devices per row, with a number selectedto yield a desired or pre-defined operational value. Several energystorage device assemblies 10 can be coupled together in a plurality ofconceivable mounting variations, such as being stacked together, placedside-by-side, etc. (e.g., FIGS. 2, 6, 7D, 8A, 8B, 11B). In addition, thelengths of energy storage devices can be altered to provide discreteoperational values for each device, and thus a different cumulativevalue for the assembly as a whole. Despite any changes in the size ofenergy storage devices, the same housing can be employed by cutting anextrusion of the housing to size, thus reducing manufacturing costs andcomplexity and providing flexibility in customizing for each differentassembly's operational performance.

In some embodiments, energy storage device assembly 10 can include afirst plate 12 and a second plate 14 located at opposing ends of ahousing of energy storage device assembly 10. In some embodiments, andas further described herein, embodiments of the invention can includehousings in the form of an elongated sleeve housing 20. Elongated sleevehousing 20 can be configured to contain various devices for electricallystoring energy, including capacitor cells, ultracapacitors, batteries,and similar components. First and second plates 12, 14 can be located atopposing ends of elongated sleeve housing 20. First and second plates12, 14, can include apertures 25 dimensioned to complement terminals 26of devices 100, which can have connectors 28 mounted thereon, allowingthem to pass through aperture 25. One or more terminals 26 can be madefrom an electrically conductive material, and terminals 26 can extendsubstantially through first or second plates 12, 14 via one or morecorresponding apertures 25. First plate 12, second plate 14, andelongated sleeve housing 20 can also substantially enclose or fluidlyisolate the contents of energy storage device assembly 10 and can beconnected via adhesives, bolts, clasps, and/or any other means ofconnection. Together, as will be described herein, first plate 12 andsecond plate 14 can define a structural thermal bridge 50, which canallow thermal communication between elongated sleeve housing 20 and itscontents or the environment beyond energy storage device assembly 10.

Turning to FIG. 2, an exploded view of an embodiment of energy storagedevice assembly 10 is shown. Energy storage device assembly 10 caninclude an elongated sleeve housing 20, with optional contours 60,surrounding energy storage devices 100. Optional contours 60 cancomplement and/or allow (thermal and/or actual) contact betweenelongated sleeve housing 20 and at least some or all of energy storagedevices 100. Contours 60 allow a portion of each energy storage device100 to contact elongated sleeve housing 20. In addition, energy storagedevices 100 can be arranged to be in two lateral rows (along Z axis),with each row containing any desired number of energy storage devices inan axial direction (along X axis). In this fashion, each energy storagedevice 100 contacts (thermally and/or actually) elongated sleeve housing20 without any energy storage devices 100 being separated from housing20 by another energy storage device. In the embodiment shown, threelateral columns (along Y axis) are provided, creating a ‘six pack’configuration (Z-Y plane). It should be recognized, however, that moreor fewer columns may be provided. In any event, assembly 10 can be sizedto any length capable of providing the desired operational performance(e.g., predetermined levels of voltage and/or capacitance). Energystorage devices 100 can be any device capable of storing electricalenergy, including capacitor cells, ultracapacitors, batteries,electrical cells, and other similar components.

The embodiment in FIG. 2 is shown to include six axial rows (in X-axis)of energy storage devices 100, arranged in a six-pack or side-by-sidefashion. The modular design of energy storage device assembly 10 andelongated sleeve housing 20 allow adjustment for accommodating energystorage devices 100 of different sizes and numbers. In an exampleembodiment, energy storage device assembly 10 can include modular asix-pack of energy storage devices 100 (e.g., FIGS. 2, 8B). Elongatedsleeve housing 20 can be provided in varying shapes and dimensions tosubstantially complement, retain, and/or matingly receive energy storagedevices 100. Retaining contact and/or mating engagement between energystorage devices 100 and elongated sleeve housing 20 can restrictmovement of energy storage devices 100 within elongated sleeve housing20 and/or provide thermal communication between energy storage devices100 and elongated sleeve housing 20.

In some embodiments, elongated sleeve housing 20 can substantiallysecure a position of energy storage devices 100 relative to one anotherand/or elongated sleeve housing 20. Elongated sleeve housing 20 caninclude an electrically and/or thermally conductive material, includingaluminum and similarly conductive metals. To provide a constantcross-sectional area, elongated sleeve housing 20 can be manufactured byextrusion and cut to a desired length. Forming elongated sleeve housing20 by extrusion, and later cutting it to the length desired for a designparameter, allows energy storage device assembly 10 to be customized andshaped to have different lengths, contain different numbers of energystorage devices 100, and/or provide other adjustments without changingthe structure of elongated sleeve housing 20 and/or energy storagedevice assembly 10.

Energy storage devices 100 can have a generally cylindrical geometry, asshown in FIG. 2, with a first projecting electrode 102, “projecting”from the end surface of energy storage device 100 at one end, and asecond projecting electrode 104, similarly “projecting” from the endsurface of energy storage device 100 at another end. As will bediscussed in further detail below, first and second projectingelectrodes 102, 104 can be substantially similar or uniformly sized oneach energy storage device 100. Each energy storage device 100 caninclude first and second projecting electrodes 102, 104, which can beconfigured for several energy storage devices 100 to be connected toeach other in series, as shown in FIG. 2. Two or more projectingelectrodes 102, 104 of energy storage devices 100 can further include orbe circumferentially connected to terminals 26. Terminals 26 can beeither positive or negative contacts to act as electrical inputs andoutputs, through which external circuits and devices can electricallyaccess energy storage devices 100. Assembly 10 can further include firstplate 12, and a first gasket 112 for sealing components within theassembly against first plate 12. Similarly, assembly 10 can furtherinclude second plate 14, and/or a corresponding second gasket 114 forsealing components within the assembly against second plate 14. Firstplate 12, first gasket 112, second plate 14, second gasket 114, andelongated sleeve housing 20 can thus be configured to substantiallyenclose and/or fluidly seal energy storage devices 100.

In some embodiments, assembly 10 can include a first thermal plate 122located proximal to first plate 12 and/or a second thermal plate 124located near or proximal to second plate 14. First and second thermalplates 122, 124 can have any material composition capable ofcommunicating thermal energy and/or insulating electricity. For example,first and second thermal plates can include a thermal transmittingmaterial, such as a plastic, epoxy, phase change material, and/or othersimilar and equivalent substances currently known or later developed.First thermal plate 122 and/or second thermal plate 124 can includecontoured recesses 115 designed to matingly receive or retain energystorage devices 100 and/or their projecting electrodes 102, 104. Sets ofcontoured recesses 115 can provide an interference or plug-style fitwith projecting electrodes 102, 104 and/or a circumferential fit withenergy storage devices 100 themselves, thereby securing a position ofenergy storage devices 100 within elongated sleeve housing 20. In someembodiments, energy storage devices 100 can be substantially securedand/or retained between first thermal plate 122 and second thermal plate124 by being connected at first and second projecting electrodes 102,104 and/or surrounding structure to first and second thermal plates 122,124.

Thermal plates 122, 124 are shown by example in the accompanying figuresas being in the form of a continuous unit. It is also understood thateach thermal plate 122, 124 can be in the form of several smallerplates, or that thermal plates 122, 124 may each be part of a largerthermal conduction assembly (e.g., FIGS. 2, 12). Other embodiments ofthe present disclosure can also include thermal insulation along theside of one or more energy storage devices 100, as an addition oralternative to thermal insulation at opposing ends of a particular row(e.g., FIG. 8). Thermal plates 122, 124 can offer several commercial andtechnical advantages, three examples of which include a high degree ofheat transfer, improved structural support (including resistance toshocks and vibrations), and lower manufacturing costs.

Assembly 100 can further include one or more bus bars 130 for electricalcoupling between energy storage devices 100, e.g., by way of projectingelectrodes 102 and 104, directly or through intervening components suchas electrodes. Bus bar 130 can optionally allow several projectingelectrodes 102, 104 of adjacent energy storage devices 100 to beconnected to each other. In this context, the term “adjacent” can referto two or more cells locations that are immediately next to each other.Hence, bus bar 130 can connect or couple two or more energy storagedevices 100 through physical connections, electrical connections,thermal connections, and other applicable forms of coupling.

As will be discussed in further detail herein, assembly 100 can furtherinclude a circuit board 140 coupled to energy storage devices 100. Insome embodiments, a particular type of wiring harness used uniformly foreach energy storage device 100, can provide electrical coupling betweencircuit board 140 and energy storage devices 100. In addition, an I/Oconnector 142 may be located on elongated sleeve housing 20 and coupledto circuit board 140 to provide an interface between circuit board 140,energy storage devices 100, and a user. Additional details regardingvarious embodiments of assembly 100 are discussed herein.

An embodiment of the disclosure, illustrated in FIGS. 3-5, provides anenergy storage device assembly 10 including a plurality of energystorage devices 100, such as capacitors, capacitor cells, ultracapacitorcells, and other components used to store energy. Each energy storagedevice can further include first projecting electrode 102 and secondprojecting electrode 104. First and second projecting electrodes 102,104, are depicted as projecting from the surface of energy storagedevices 100 at opposite ends and having corresponding substantiallycircular shapes. However, the disclosure also contemplates electrodesdesigned to have other shapes and geometries. To improve performance andreduce the use of components with relatively high resistances, such aspreviously discussed bus bars 130, one or more weld bonds 210 can beprovided for direct bonding between adjacent first and second projectingelectrodes 102, 104 of adjacent energy storage devices 100. Weld bonds210 can therefore allow several energy storage devices 100 to beelectrically connected to each other in series.

These series connections allow energy storage devices 100 to be linkedin a chain of weld bonds 210 (also referred to herein as joints),allowing assembly 10 to be customizably scaled to applications wheremore or fewer energy storage devices 100 are desired. Furthermore,series connections between energy storage devices 100 can allow the sameor similar housings to enclose variable lengths of energy storagedevices 100. In some cases, housings or enclosures for energy storagedevices 100 can be manufactured by extrusion and then dimensioned (e.g.,by cutting) to separate a desired number of energy storage devices 100having a predetermined operational value, such as a capacitance orvoltage.

Turning to FIG. 3, a portion of energy storage device assembly 10 isshown and can include several energy storage devices 100. In someembodiments, energy storage devices 100 can be connected together inseries. For example, energy storage devices 100 can be connected end toend, between first and second projecting electrodes 102, 104. Individualenergy storage devices 100 can be connected to one another directly,without intervening elements, between projecting electrodes 102, 104 ofenergy storage devices 100 through weld bonds 210. An end-to-endconfiguration shown in FIGS. 3 and 4 for connecting energy storagedevices 100 in series can further reduce the need for horizontal spaceas compared to situations where energy storage devices are placed in aside by side configuration. In some embodiments, energy storage devices100 may be connected with weld bonds 210. Weld bonds 210 can be formedthrough a spot weld, a circumferential weld, a TIG (gas tungsten arc)weld, a MIG (gas metal arc) weld, an EB (electric) weld, a laser weld,or any other types of welding currently known or later developed. In oneembodiment, laser welding can be used to form weld bond 210 by weldingfirst and second projecting electrodes 102, 104 of energy storagedevices 100 together along a single circumferential line of eachimmediately adjacent (X-axis FIG. 2) energy storage device 100.

Joining electrical storage devices 100 in this fashion can reduce thenumber of bus bars 130 used to connect ends of energy storage devices100, as compared to assemblies in which energy storage devices arearranged in a structurally parallel fashion. Since bus bars 130 can havea relatively high level of electrical resistance, reducing their usealso reduces resistance in the electrical connections provided betweenenergy storage devices 100 used in assembly 10.

Turning to FIGS. 3-4, an end-to-end configuration of an energy storagedevice assembly 10 can include a plurality of energy storage devices100, and each of these units in the plurality can include firstprojecting electrode 102 and second projecting electrode 104 at opposingends of each energy storage device 100. As shown previously, energystorage devices 100 can be joined directly by a weld bond 210 betweenfirst projecting electrode 102 and second projecting electrode 104.Several weld bonds 210 can be implemented between pairs of energystorage devices 100 such that all or a portion of the plurality ofenergy storage devices 100 are electrically connected to each other inseries.

As can be seen in FIG. 4, a first projecting electrode 102 of an energystorage device 100 can be connected to a second projecting electrode 104of an adjacent energy storage device 100 via weld bond 210, therebysecurely connecting energy storage devices 100 in series, optionallyalong a single circumferential line of contact. First and/or secondprojecting electrodes 102, 104 can also include a fastener 212, whichcan allow an electrical lead or contact 215 to be coupled to a jointbetween two energy storage devices 100.

Fastener 212 can take the form of a rivet that is inserted betweenenergy storage devices 100 by driving a fastener 212 into firstprojecting electrode 102, second projecting electrode 104, or weld bond210. Fastener 212 can be connected to wire 215 before being inserted, orwire 215 can be electrically coupled to fastener 212 after installation.Wires 215 coupled to fastener 212 can be used for coupling voltages orelectric currents in energy storage devices 100 other locations,including sites in assembly 10, e.g., circuit board 140 (shown in FIG.2). In some embodiments, a plurality of fasteners 212 can further beprovided at series connections of energy storage devices 100 at aplurality of weld bonds 210 and/or projecting electrodes 102, 104,thereby joining a plurality energy storage devices 100 to circuit board140 (shown in FIG. 2) via several wires 215.

Turning to FIG. 5, an example procedure for welding several energystorage devices 100 together is shown. Two or more energy storagedevices 100 to be connected by a series connection can be positioned ontop of rollers 212. For additional stability and ease of manufacture, athird roller 212 can be provided above and adjacent to energy storagedevices 100 subject to welding. The energy storage devices 100 to beconnected can also be aligned at their first and second protrudingelectrodes 102, 104. One or more laser welders 214 can be positionedproximate and/or above energy storage devices 100, such that laserwelders 214 are each substantially aligned with points or surfaces ofcontact between energy storage devices 100. Laser welders 214 can thentransmit welding beams 216 to energy storage devices 100 and form one ormore weld bonds 210 between energy storage devices 100 as rollers 212turn to rotate energy storage devices 100.

In some embodiments, the welding process can be simplified by keepinglaser welders 214 stationary and imparting rotational motion 215 toenergy storage devices 100 by actuating or applying energy to rollers212, thereby providing the entirety of weld bond(s) 210 in a uniformfashion. In other embodiments, energy storage devices 100 can bestationary, while laser welders 214 rotate about the circumference ofenergy storage devices 100 to apply a laser welds through welding beams216. Laser welder 214 can form weld bond 210 by varying the temperatureof beams 216 as necessary (e.g. 3000° F., 2000° F., 1200° F., etc.).Further, it is understood that embodiments of the present disclosure arenot limited to laser welding processes. Several energy storage devices100 can also be bonded together with EB (electric), TIG (Tungsten Arc),and MIG (gas metal arc) welds if desired, in addition to any otheradapted form of one or more currently known or later developed weldingtechniques.

Further embodiments of assembly 10, examples of which are included inFIGS. 6-8B, can include thermal transmitting mechanisms forconducting/transmitting heat from energy storage devices 100. In oneembodiment, a thermal transmitting mechanism may include a thermaltransmitting material, such as a plastic, resin, epoxy, phase-changematerial, or similar substance configured to communicate heat fromenergy storage devices 100 to other components, such as an elongatedsleeve housing 20. As will be described in further detail below, thermaltransmitting mechanisms can be provided as additional components withinenergy storage device assembly 10 that may, for example, be applied toenergy storage devices 100, housings such as elongated sleeve housing20, or other components. For example, as will be described herein,thermal transmitting mechanisms can be affixed to weld bonds 210,applied as a coating to the surface of energy storage devices 100,coated inside of housings such as elongated sleeve housing 20, and/or beprovided as a liquid or solid substance interposed between energystorage devices 100 and a housing, such as elongated sleeve housing 20.The embodiments discussed with respect to each of FIGS. 6-8B each embodyone or more thermal transmitting mechanisms, and other substantiallysimilar mechanisms capable of insulating electricity while thermallyconducting heat within and from energy storage device assembly 10.

Referring to FIGS. 6-7C, energy storage device assembly 10 can includethermal transmitting mechanisms in the form of one or more thermalinserts 220 between two energy storage devices 100. Thermal insert 220is shown in FIG. 6 by way of example as being positioned about first andsecond projecting electrodes 102, 104 between energy storage devices100. It is also understood that thermal insert 220 can be adapted to bepositioned about several energy storage devices 100 simultaneously.Thermal insert 220 can have a material composition of plastic or similarsubstance capable of insulating an electrical current while transmittingheat from energy devices 100 and offering structural support. Energystorage devices 100 can contact enclosures or the elongated sleevehousing 20 (FIG. 2) through thermal insert 220, which in turn can act asa bridge or transitional component. The configuration of thermal insert220 optionally allows heat to be communicated from energy storagedevices 100 without altering the connection between them, including weldbonds 210 such that one or more thermal inserts 220 can be added to orremoved from energy storage device assembly 10 as desired. Though FIG. 6depicts only one thermal insert 220, embodiments of the disclosure canuse any number of thermal inserts at connections between energy storagedevices 100 to suit varying design requirements.

Thermal insert 220 can offer further customization when provided with asnap-fit design shown in FIGS. 7A-B. In some embodiments, thermal insert220 can include sub portions 222, which can be installed on oppositesides of coupled first and second projecting electrodes 102, 104.Thermal insert 220 and its combined sub-portions 222 can have a rampedor sloped geometry, provided by axial protrusions 227, allowing for agreater area of contact between thermal insert 220 and energy storagedevice 100 on one side, and a lesser area of contact between thermalinsert 220 and another energy storage device 100 on another side. Asdiscussed below in the discussion accompanying FIG. 7D, this geometryallows thermal inserts 220 to be installed with alternatingorientations, permitting a plurality of similar or substantiallyidentical thermal inserts 220 to be used in one energy storage deviceassembly 10. As used in this specification, the term “substantiallyidentical” refers to any two or more components which are identical ordesigned to be identical, accounting for minor or unexpected deviationswith no effect on the component's performance, e.g. differences orerrors caused during manufacture. Thermal insert 220 can include anynumber of thermal transmitting and electrically insulative materials,including plastics, phase-change materials, and/or other known and laterdiscovered substances capable of communicating heat while insulatingelectricity. Thermal inserts 220 according to this embodiment are thuscapable of being affixed and removed from electrodes 102, 104 withoutdestroying weld bond 210, allowing a single assembly 10 to be adapted todifferent situations. In some embodiments, thermal inserts 220 can beused as an “internal structural thermal bridge” because of their abilityto conduct heat while insulating electricity and structurally locatingdevices 100 relative to housing 20.

Sub-portions 222 can be configured to join with each other by a snapjunction, coupling, or similar mechanical connection 226, therebyallowing thermal insert 220 to enclose a cross sectional area that issubstantially equal to first and second electrodes 102, 104 but lessthan the cross sectional area of energy storage devices 100. Althoughsub-portions 222 can have mechanically distinct designs, sub-portions222 can also be identical, and may feature mating contact points onopposing sides of a semi-circle. In some embodiments, thermal inserts220 can allow wires 215 (FIG. 4) to run through thermal inserts 220without being obstructed by them or impairing the transmission ofelectricity through the wires. Thermal insert 220 can be assembled byjoining sub-portions 222 together at mechanical connections 226, forinstance by inserting a protrusion 224 into a receiving slot 225. Asshown in FIG. 7B, one sub-portion 222 can be substantiallysemi-circular, including protrusion 224 on one side of sub-portion 222and receiving slot 225 on another side. Other variants of sub-portions222 can include designs with three or more components, or withgeometries that are not substantially circular.

Turning to FIG. 7C, a design that can be used for some embodiments ofthermal insert 220 is shown. FIG. 7C shows energy storage device 100 andprojecting electrode 102 extending axially therefrom, with additionalenergy storage devices and weld bond 210 (FIGS. 2, 3, 4) omitted for thesake of demonstration. Thermal insert 220 is shown to have axialprotrusions 227, with a sloped geometry and extending from approximatelythe circumference of energy storage device 100 to approximately thecircumference of projecting electrode 102. The geometry of thermalinsert 227 depicted in FIG. 7C therefore can contact energy storagedevice 100 at a greater surface area on one side, while contactinganother energy storage device (not shown) on the other side.

FIG. 7D illustrates an advantage of designing thermal inserts 220 tohave different surface areas on opposing sides through use of axialprotrusions 227. In FIG. 7D, energy storage device assembly 10 is shownto include several energy storage devices, with thermal inserts 220provided alongside weld bonds 210. Each thermal insert 220 can includeaxial protrusions 227, allowing for adjacent thermal inserts 220 to havealternating orientations. The alternating orientations allow eachthermal insert 220 to have similar or substantially identical thermaldesigns, increasing both the scalability of energy storage deviceassembly 10 and any thermal communication between the variouscomponents.

As demonstrated by example in FIGS. 8A-8B, in another embodiment, eachenergy storage device 100 may include one or more thermal conductinglayers 230 thereon, which can be provided in the form of coatings orlayers 230 (hereinafter simply ‘thermal layers’). Thermal layers 230 canbe mounted on, placed on, or otherwise coupled or attached to energystorage devices 100, housings such as elongated sleeve housing 20 (FIG.2), first and second thermal plates 122, 124 (FIG. 2), or any othercomponent of energy storage device assembly 10. In other embodiments,thermal conducting layers 230 can generally be interposed between energystorage devices 100 and a housing, such as elongated sleeve housing 20(FIG. 2). Thermal conducting layers 230 can be made from a material thatallows heat to be transferred from energy storage device 100 into othercomponents of an assembly 10, such as elongated sleeve housing 20.Similar to thermal insert 220, several thermal conducting layers 230 canbe provided within assembly 10, allowing one or more thermal layers 230to be included on one energy storage device 100 and/or on several energystorage devices 100. As energy storage devices 100 are arranged in tworows, each thermal layer 230 can be capable of transferring thermalenergy directly to elongated sleeve housing 20 through thermal contact.Thermal layers 230 are shown in FIG. 8A as having substantiallyrectangular geometries that are shaped to match the substantiallycylindrical outer surfaces of devices 100, but other geometries,including substantially quadrilateral, circular, and/or any simple orcomposite shape capable of being set upon or affixed to energy storagedevices 100 are contemplated.

Including one or more thermal layers 230 can communicate or dissipateaccumulated heat from energy devices 100 caused from operating assembly10. Thermal layers 230 can assist in communicating heat from energystorage devices 100 to other areas within and outside energy storagedevice assembly 10, without being directly interposed between energystorage devices 100 at weld bonds 210. Either or both of thermal layers230 and thermal inserts 220 can allow all of energy storage devices 100to contact another component, such as a housing of assembly 10.Assemblies that include serial weld bonds 210 between energy storagedevices 100 can be used, with or without any of the previously describedmodifications, along with any of the further additional components thatcan be included in energy storage device assembly 10. Thermal layers 230can take the form of any now known or later developed material includingbut not limited to: a resin, an epoxy, or a phase change material.Thermal layers 230 can be selectively applied to the exterior of energystorage devices 100 and/or an interior of elongated sleeve housing 20(FIG. 2) in any now known or later developed fashion, e.g., adhesion ofa layer, coating, dipping, etc., that allows for quality thermalconduction.

In another embodiment, shown in FIG. 8B, thermal transmitting mechanismmay include a thermal filler 232. Thermal filler 232 can be provided asa resin, an epoxy or a phase change material. Thermal filler 232 can beinstalled by pouring, sliding, or mechanically inserting using any knownor later developed process. As demonstrated in FIG. 8B, thermal filler232 may take the form of a single, continuous component enclosing eachenergy storage device 100. In some embodiments, thermal filler 232 canbe shaped with the same or similar contours 60 as elongated sleevehousing 20 (FIG. 2), and thereby transmit heat from energy storagedevice 100 to other components of energy storage device assembly 10and/or an exterior environment. In another embodiment, thermal filler232 can be partially applied by providing a resin, epoxy, phase-changematerial, or similar thermally conductive and electrically insulativematerial around energy storage devices 100 and/or within elongatedsleeve housing 20 (FIG. 2), in a liquid or dry state.

Thermal filler 232 thus can take a shape that fills some or all of anygaps between energy storage devices 100 and an enclosure or elongatedsleeve housing 20, while also surrounding any wires 215 (FIGS. 4, 8A)present within elongated sleeve housing 20 (FIG. 2). Thus, thermalfiller 232 can be customized to take the form of individual units or acontinuous unit, as may be desired for various deployments.

It is understood that the described thermal inserts 220 and/or thermalfiller 230 may be used alone or in combination, and that the materialsthat make up the mechanisms may be customized to accommodate differentthermal loads. For example, thermal transmitting mechanisms in someembodiments can include only one of a resin, epoxy, phase changematerial, or similar substances currently known or later developed. Inaddition, the chemical compositions of each thermal transmittingmechanism may be customized to provide a particular thermaltransmissivity.

An embodiment of the invention provides a housing in the form of anelongated sleeve housing. An example of an elongated sleeve housing, andaccompanying components that can be used with embodiments of theinvention, are shown in FIGS. 9-1 lB. In FIG. 9, elongated sleevehousing 20 is shown to be compatible with energy storage device assembly10 (FIGS. 1-6). Elongated sleeve housing 20 can have a geometryconfigured to enclose a plurality of energy storage devices 100. In someembodiments, energy storage device assembly 10 can further enclose acircuit board 140, which can be coupled to the plurality of energystorage devices 100 with at least one wiring harness 302 (shown in moredetail in FIGS. 11A, 11B).

Wiring harness 302 can include a plurality of wires (shown further inFIGS. 11A, 11B) operative to electrically couple or connect circuitboard 140 to energy storage devices 100, e.g., at joints, between energystorage devices 100 such as weld bond 210 (FIGS. 2, 3, 4). In someembodiments, circuit board 140 can be positioned along a length ofhousing 20 and retained within a mount 304 located within the interiorof housing 20. As shown in FIG. 10, in one embodiment, elongated sleevehousing 20 includes mount 304 in the form of opposing slots that engageopposing sides/edges of circuit board 140 to allow circuit board toslidably engage elongated sleeve housing 20 and be retained therein.Other forms of mount 304 may also be possible. Circuit board 140 canfurther be positioned along a length of housing 20. Due to circuit board140 being positioned along a length of housing 20 and the seriespositioning of energy storage devices 100, a wiring harness 302 having asingle arrangement of wires can be used repeatedly throughout energystorage device assembly 10. In this fashion, electrical connectionsbetween circuit board 140 and each energy storage device 100 can besimplified, allowing the use of similar or substantially identical typesof wiring harnesses 302 repeatedly, regardless of the number of energystorage devices 100 (FIG. 2) or the desired size of energy storagedevice assembly 10. Using substantially identical wiring harnesses 302can lower the time and costs associated with manufacturing energystorage device assembly 10. As discussed herein, the term “substantiallyidentical” can encompass situations in which the same generic componentsare used for each wiring harness 302, even when manufacturing errorscause variations between the individual wiring harnesses 302.

The design of elongated sleeve housing 20 features a uniform crosssectional area, and can be of a customizable length, allowing the numberof energy storage devices 100 contained within to be customized withoutchanging the shape of elongated sleeve housing 20, including its crosssectional area, which can further reduce the time and cost ofmanufacture.

In some embodiments, further measures can be employed to enhance thermalcommunication between energy storage devices 100 and elongated sleevehousing 20. For example, the plurality of energy storage devices 100 canbe arranged in a plurality of rows, each row of energy storage devices100 being in thermal contact with an interior 310 of elongated sleevehousing 20. In other embodiments, at least one of the plurality ofenergy storage devices 100 can also include thermal transmittingmechanisms, e.g., in the form of thermal layer 230 and/or thermal filler232, shown previously in FIGS. 8A, 8B, interposed between the elongatedsleeve housing 20 and at least one energy storage device 100.

In some embodiments, the elongated sleeve housing 102 can also include aplurality of interior grooves 312. Interior grooves 312 can be locatedwithin interior 310 of elongated sleeve housing at any desired position,as demonstrated by example in FIG. 9. Grooves 312 can retain one or morebolts or screws for coupling first and second thermal plates 122, 124(FIG. 2).

Embodiments of elongated sleeve housing 20 include designs in whichelongated sleeve housing 20 is a single component of substantiallyuniform cross sectional area, as depicted in FIGS. 9 and 10. Suchdesigns allow for elongated sleeve housing to be manufactured with anydesired length in which a set number of energy storage devices 100 canbe contained within a cross sectional area of elongated sleeve housing20. As a result, elongated sleeve housing 20 can allow energy storagedevice assembly 10 to be scalable to any desired length, and a desirednumber of series electrical connections between energy storage devices100 can be provided in each implementation of assembly 10. Energystorage assembly 10 can be scaled as desired by manufacturing elongatedsleeve housing 20 by extrusion to varying lengths of substantiallyuniform cross sectional area. The extruded elongated sleeve housing 20can then be cut to size to enclose a desired number of energy storagedevices 100, such that energy storage device assembly 10 can have apredetermined operational value, e.g., a predetermined voltage orcapacitance.

Turning to FIG. 11A, an additional embodiment of elongated sleevehousing 20 is shown. Circuit board 140 is shown to be retained withinelongated sleeve housing 20. Wire harnesses 302 can couple circuit board140 to several wires 215, which can be provided as single wires, groupsor wires, or an extension of a wire harness 302. Wires 215 thus can beelectrically connected or coupled to first and/or second projectingelectrodes 102, 104 of energy storage devices.

In FIG. 11B, a more detailed illustration of an embodiment of assembly10 is shown. As was discussed with respect to FIG. 11A, circuit board140 can be connected to several wires 215 through wire harnesses 302.Each wire 215, which can be provided singly, in a group, or as part of awiring harness, can electrically connect circuit board 140 to at leastone of energy storage devices 100.

As is further shown in FIG. 11B, consistent electrical couplings bywiring harnesses 302 can be provided in conjunction with providingthermal transmitting material, such as the previously discussed thermalinserts 220, thermal layers 230, and/or thermal filler 232. Each wiringharness 302 shown in FIG. 11B is shown as substantially identical to theothers, allowing each connection between energy storage devices 100 andcircuit board 140 to be consistent. Consistency or identity between eachwiring harness 302 can also allow installation of thermal transmittingmechanisms (shown elsewhere), e.g., inserts (which can be furtherconfigured to retain wires 215 as discussed previously), thermal layers,and/or thermal filler. In some embodiments, wiring harnesses 302 can beused in user-customized or varying energy storage assemblies 10 withoutbeing redesigned or otherwise altered to have different lengths, therebydecreasing manufacturing time and costs.

As shown in FIG. 12, assembly 10 can further include first thermal plate122, and second thermal plate 124, which can be coupled together to formstructural thermal bridge 50. As described herein with respect to FIG.2, and now shown in greater detail in FIG. 12, first thermal plate 122can be positioned between first projecting electrodes 102 of energystorage devices 100 and first gasket 112, and second thermal plate 124can similarly be positioned between second projecting electrodes 104 ofenergy storage devices 100 and second gasket 112. First and/or secondthermal plates 122, 124 can define apertures 25 configured to complementor matingly receive terminals 26 connected to one or more energy storagedevices 100.

As further shown in FIG. 12, thermal communication between energystorage devices 100 and other components can be increased in someembodiments by structural thermal bridge 50. In other embodiments,structural thermal bridge 50 can allow for all energy storage devices100 in assembly 10 to be thermally connected to another structure, suchas elongated sleeve housing 20. Structural thermal bridge 50 can includethermal plates 122, 124, which can be configured to restrain movement byenergy storage devices 100, provide load distribution through energystorage device assembly 10, and improve thermal conduction to othercomponents or structures, including elongated sleeve housing 20.

Recesses 115 can be shaped according to the component of an energystorage device assembly 10 that they complement or matingly engage. Forexample, recesses 115 can further be shaped to complement or matinglyengage with a bus bar 130 coupled to a projecting electrode 102, 104 ofenergy storage device 100, terminal 26, or other components. Thermalplates 122, 124 can further be engaged with gaskets 112, 114 and furthersecure thermal plates 122, 124 to elongated sleeve housing 20 and/orfirst and second plates 12, 14. Including gaskets 112, 114 in an energystorage device assembly 10 can allow thermal plates 122, 124 ofstructural thermal bridge 50 to retain energy storage devices 100 withinelongated sleeve housing 20, and thereby prevent or reduce rotationalaction against energy storage devices 100.

Structural thermal bridge 50 and/or thermal plates 122, 124 cancommunicate thermal energy throughout energy storage device assembly 10.Therefore, thermal plates 122, 124 offer structural support for energystorage devices 100, while also assisting in thermal management withinassembly 10. The amount of thermal transmission to assembly 10 providedby structural thermal bridge 50, thermal plates 122, 124, thermalinserts 220, thermal layers 230, and/or thermal filler 232 can bepredefined by selecting sizes, shapes, and materials used for thesecomponents. For example, thermal plates 122, 124 may be comprised of anythermally conductive material that also has an acceptable low bulkelectrical conductivity as compared to the material composition ofenergy storage devices 100. In some embodiments, materials used inthermal plates 122, 124 can include talc, a talc filled mineral, a talcfilled plastic and similar compositions.

Thermal plates 122, 124 can be customizably manufactured to accommodatevarious design considerations. In one example, shown in FIG. 12, firstplate 122 can be formed to include a plurality of surface segments 404.Segments 404 can further include recesses 410. For example, somerecesses 115 can be configured to mate with bus bars 130 on energystorage devices 100, while other recesses 115 can be configured to matewith terminals 16 located at first or second projecting electrodes 102,104 of energy storage device 100. First thermal plate 122 and/or secondthermal plate 124 can further include apertures 25, 411 to aid inthermal conduction and/or internal clearance.

Turning to FIG. 13, structural thermal bridge 50 and/or thermal plates122, 124 can be provided with apertures 402, surface segments 404,and/or other structural components. As described herein, surfacesegments 404 of thermal plates 122 and 124 can each include a pluralityof recesses 115, which can be configured as ribs, ridges, and/orindentations. Each recess 115 can be configured to complement all orpart of an energy storage device 100, including projecting electrodes102, 104 (shown in FIGS. 2, 4, 6, 7).

First and second thermal plates 122, 124 can also include severalsegments 404, including two or more recesses 115 defined by a set ofridges 412, which can complement or matingly receive various components,such as bus bar 130. First and/or second thermal plates can furtherinclude a terminal recess 426 configured either to complement ormatingly receive terminal 26. Segments 404 can include a pocket 436configured to receive at least a portion of terminal 26 and/or connector28. In some embodiments, pocket 436 can project from surface 404.

FIG. 14 illustrates an interface between terminals 26 and segments 404of first or second thermal plates 122, 124 according to an embodiment.Terminal 26 can be connected to energy storage device 100 beforeengaging segments 404 or other corresponding structure of structuralthermal bridge 50. Elongated sleeve housing 20 is shown to be coupled toseveral energy storage devices 100, which can be connected to each otherin series, e.g., at their first and second projecting electrodes 102,104. A plurality of wiring harnesses 302 can couple circuit board 140 toenergy storage devices 100, such that electrical communication betweeneach energy storage device 100 and circuit board 140 is provided. Asdiscussed herein with respect to FIG. 4, fasteners 212 can allow wiresor wire leads from wiring harnesses 302 to be electrically coupled toenergy storage devices 100.

In some embodiments, the scalable length of elongated sleeve housing 20and its physical contact with each enclosed energy storage device 100allows each wiring harness 302 to be similar or substantially identicalto each other. Using substantially identical wiring harnesses 302, whenpermitted by elongated sleeve housing 20, allows each energy storagedevice 100 to be connected to circuit board 140 according to a uniformdesign.

Turning to FIG. 15, assembly 10 can include a set of terminals 26 foruse with energy storage devices 100. Terminals 26 can be shapeddifferently from previously known terminals. For example, inconventional assemblies, a terminal could comprise a cup that sits on acapacitor and totally encloses an end or tip of the capacitor. As such,this terminal would traditionally press-fit or be welded radially at apoint where the terminal contacts the capacitor, to secure the terminalto the capacitor. In contrast, disclosed terminals 26 can include a setof arcuate flanges 502 which provide circumferential connection to firstor second projecting electrodes 102, 104 of energy storage device 104.

Arcuate flanges 502 can be disposed proximate one another and/or beseparated by a set of notches 504. Notches 504 can enable set of arcuateflanges 502 to be adjustable or bendable relative one another, and/orallow connection to energy storage device 100. Terminal 26 can alsoengage or connect to projecting electrodes 102, 104 of energy storagedevice 100. In this context, connections can be provided throughinterfaces such as press fits, snap fits, interference fits, and/ormatingly engagable parts. A first set of apertures 506 may be located inset of arcuate flanges 502 to aid in electrically connecting terminals26 to circuit board 140, optionally through wiring harness 302. A secondset of apertures 508 can be provided to couple terminals 26 topreviously described first and second plates 12, 14, first and secondthermal plates 122, 124, and/or elongated sleeve housing 20.

Terminal 26 can include connector 28, which can protrude from terminal26, optionally through one of the first and second plates 12, 14 and/orone of the first and second thermal plates 122, 124 for electricalcontact between energy storage devices 100 and components, e.g.,equipment outside energy storage device assembly 10. In someembodiments, connector 28 defines a terminal aperture 510, which can beconfigured to matingly receive an electrical contact and/or adapter toprovide electrical contact. In an embodiment, terminal aperture 510 caninclude threads 512, which thereby can allow terminal 26 to connect witha threaded plug (not shown).

In another embodiment, connector 28 can define a connector surface 514configured to connect to a plug, application, and/or a tool. Connectorsurface 514 can be in the form of a patterned surface, flattenedsurface, or similar geometry for engaging other components. Connector 28can be substantially centrally located relative to set of arcuateflanges 502, and can directly contact energy storage devices 100. A gap520 can be present between sets of arcuate flanges 502 and connector 28.Gap 520 can be configured to matingly receive projecting electrodes 102,104 of energy storage device 100 and provide access to an interface 530(shown in FIG. 16) between connector 28 and energy storage device 100.

In some embodiments, terminal 26 can be welded circumferentially onprojecting electrodes 102, 104 of energy storage devices 100. Forexample, as shown in more detail in FIG. 16, assembly 10 can includeterminal 26, welded circumferentially to first or second projectingelectrode 102, 104 along interface 530 between set of flanges 502 andfirst or second projecting electrode 102, 104. Terminal 26 is furthershown to be aligned circumferentially about a first or second projectingelectrode 102, 104, and can connect to energy storage device 100 alongweld region 532.

A process for engaging terminal 26 on energy storage device 100 is shownin further detail in FIGS. 17, 18. FIG. 18 shows an embodiment withwhich a weld joint 532 can be formed at or applied to interface 530 viaaccess created by gap 520. Following formation of weld joint 532, asshown in FIG. 18, second plate 124 can matingly engage or contact energystorage devices 100 and/or terminal 26 such that connector 28 extendsthrough aperture 25. Furthermore, terminal 26 can be dimensioned tomatingly engage second plate 124. In this configuration, torque impartedby tightening a terminal fastener 540 in to terminal 26 can bedistributed to other energy storage devices 100 in assembly 10, therebyreducing direct torque on welded areas about terminal 26.

As shown in FIG. 19, assembly 10 can also include one or more bus bars130 to connect parallel sets of energy storage devices 100. A notchedbus bar 130 according to an embodiment of the disclosure can be made ofan electrically conductive material such as metals, e.g., aluminum,steel, tin plated copper, etc. Bus bar 130 can connect groups of seriesenergy storage devices 100, or can group together parallel sets ofenergy storage devices 100. Similar to terminal 26 discussed previously,bus bar 130 can be circumferentially connected to a projecting electrode102, 104 of energy storage devices 100. Each bus bar 130 can communicateelectricity between the adjacent energy storage devices 100 coupledthereto.

An embodiment of notched bus bar 130 is shown in FIG. 20. Notched busbars 130 can be configured to connect energy storage devices 100 attheir projecting electrodes, 102, 104. Bus bar 130 can include a base602 and one or more bus flanges 604 connected to base 130. One or morebus flanges 604 can extend from base 602 and can engage or connect withprojecting electrode 102, 104 of an energy storage device. Bus flanges604 can be dimensioned to have varying geometries, including arcs, rigidlines, crescent-type geometries, or other geometries as may be desired,in order to provide contoured regions of contact between bus bar 130 andenergy storage devices 100.

Bus flanges 604 can be shaped to form notch 610, which can improveflexibility of bus flanges 604 to allow notched bus bar 130 to beinstalled on an energy storage device. Notch 610 can further allow busflanges 604 to flex within the plane of body 602, such that one of busflanges 604 may be spatially displaced from another. Spatialdisplacement between bus flanges 604 can improve the contour of contactareas between bus bar 130 and energy storage device 100. Thisflexibility can provide a secure electrical connection betweenindividual energy storage devices 100 and bus bar 130 without riskingelectrical shorts, current leakage, etc. In some cases, bus flanges 602can reduce or even neutralize external forces acting against energystorage devices 100. Notched bus bars 130 can also be bonded orotherwise affixed to energy storage devices 100 through welding or otherforms of structural bonding to increase stability of energy storagedevice assembly 610.

Bus flanges 602 can be shaped to form two or more substantially circularends 620, with each end 620 connected through base 602. Generally,substantially circular ends 620 can also be substantially circular.Substantially circular ends 620 can thus be configured to engagecircumferentially one of the projecting electrodes 102, 104 of an energystorage device 100. Substantially circular ends 620 can thereforegeometrically accommodate energy storage devices 100 of varyinggeometrical design. Substantially circular ends 620 can be configured tobe partially circular, instead of completely circular, to avoidsituations in which exact geometrical alignment between bus bar 130 andenergy storage devices 100 would be necessary. Thus, substantiallycircular ends 620 can engage either projecting electrode 102, 104 ofenergy storage devices 100 without completely enclosing the device.

Some advantages offered by including one or more substantially circularends 620 in bus bar 130 can include an ability to connect bus bars 130to energy storage devices 130 through a light press fit, and theadaptability of bus bar 130 to design or manufacturing variances betweennumerous energy storage device assemblies 10. Furthermore, any desirednumber of bus bars 130 can be used to connect energy storage devices 100in energy storage device assemblies 10, improving the structuralstability and operability of the previously discussed components, suchas structural thermal bridge 50, plates 12, 14, and/or thermal plates122, 124.

Turning to FIG. 21, an embodiment of a cooling system 700 for one ormore energy storage device assemblies 10 is shown. As discussed hereinenergy, storage device assembly 10 can include a plurality of energystorage devices 100 (e.g., ultracapacitors) therein. Each energy storagedevice 100 can include first electrode 102 and second electrode 104 atopposing ends, which may be electrical terminals with oppositepolarities. As is also discussed herein, several energy storage devices100 of energy storage device assembly 10 can be connected to one anotherin series. Energy storage device 10 can include elongated sleeve housing20, in which several series connections of energy storage devices 100can be enclosed.

Cooling system 700 can include a liquid coolant transmission line 702 inthermal communication with at least one energy storage device 100 ofenergy storage device assembly 10. Liquid coolant transmission line 702can be located in close proximity to energy storage device 100 (e.g.,separated by a distance with an order of magnitude of decameters,centimeters, millimeters, etc.). During operation, one or more energystorage devices 100 may accumulate heat to be dissipated to othercomponents of energy storage device assembly 10 (e.g., elongated sleevehousing 20, structural thermal bridge 50 (FIGS. 1, 12)). To reducetemperatures about energy storage device 100 and/or other components ofenergy storage device assembly 10, liquid coolant transmission line 702can be composed of a thermally-conductive, electrically-insulatingmaterial which absorbs some accumulated heat from at least one energystorage device 100. In an embodiment, a portion of liquid coolanttransmission line 702 can be positioned adjacent to and substantiallyacross a length of adjacent energy storage devices 100, therebyabsorbing heat from two or more adjacent energy storage devices 100. Toincrease the rate and magnitude of heat transfer, liquid coolanttransmission line 702 may transmit one or more substances capable ofabsorbing heat without affecting its physical properties. Asnon-limiting examples, liquid coolant transmission line 702 cantransmit: an antifreeze, a compressible refrigerant, an antifreeze-watersolution, and/or other currently known or later developed materials withsimilar heat transfer properties. Liquid coolant transmission line 702can be composed of any currently known or later developed material forcontaining and/or transmitting fluids. For example, liquid coolanttransmission line 702 can be a reinforced or non-reinforced conduitcomposed of a plastic, synthetic and/or natural rubbers, non-conductivemetals or metal alloys, resinous materials, composite materialsincluding one of the example substances discussed herein, and/or othersubstances. Where liquid coolant transmission line 702 can besufficiently electrically insulated from energy storage devices 100 byintervening gaps and/or materials, it may alternatively includeconductive metals or metal alloys. As is shown in FIG. 21, liquidcoolant transmission line 702 may include one or more joints therein,e.g., elbow joints, coupling joints, tee joints, and/or other plumbingand fitting components. In other embodiments, liquid coolanttransmission line 702 may be composed of a flexible tubular materialwhich can be worked to integrally include turns, expansions, branches,etc.

Embodiments of cooling system 700 can also include athermally-conductive, electrically-insulative material 704 through whichliquid coolant transmission line 702 passes. Thermally-conductive,electrically-insulative material 704 can be composed at least partiallyof, e.g., a plastic, a phase-change material, a potting material,combinations of the example materials described herein and/or othermaterials, and/or any other known and later discovered substancescapable of communicating heat while insulating electricity.Thermally-conductive, electrically-insulative material 704 can thus becomposed of one or more of the same materials as discussed hereinregarding structural thermal bridge 50 (FIGS. 1, 12), thermal inserts220 (FIGS. 6, 7A, 7C, 7D, 11B), thermal conducting layers 230 (FIGS. 8A,11B), thermal fillers 232 (FIG. 8B), or can be composed of a differentmaterial or combination of materials. Thermally-conductive,electrically-insulative material 704 can communicate heat from energystorage devices 100 into liquid coolant transmission line 702 and anysubstances being transmitted therein. Thermally-conductive,electrically-insulative material 704 can thus allow for a largerseparation distance between energy storage devices 100 and liquidcoolant transmission line 702 than may be possible with other substances(e.g., air, insulative structural connections, etc.) being positionedtherebetween.

As shown in FIG. 21, a portion of liquid coolant transmission line 702can extend substantially axially along (i.e., in parallel with theorientation of first and second projecting electrodes 102, 104) thelength of multiple energy storage devices 100 throughout elongatedsleeve housing 20 of energy storage device assembly 10. Turning brieflyto FIG. 22, in some embodiments, where liquid coolant transmission line702 includes a material, e.g., aluminum, capable of direct coupling toelongated sleeve housing 20, a weld bond 705 may be used. Weld bonds 705may be formed by one or more of, e.g., a spot weld, a circumferentialweld, a TIG (gas tungsten arc) weld, a MIG (gas metal arc) weld, an EB(electric) weld, a laser weld, or any other types of welding currentlyknown or later developed. Weld bonds 705 may be formed upon an interiorsurface of elongated sleeve housing 20, a protruding surface withinelongated sleeve housing 20, and/or a mounting fixture or interveningcomponent otherwise coupled to the interior of elongated sleeve housing20. Through weld bonds 705 or other types of coupling methods orcomponents, liquid coolant transmission line 702 and/or other componentsof cooling system 700 can be alternatively be directly embedded withinand/or upon (e.g., extruded with) portions of elongated sleeve housing20.

Referring now to FIGS. 23 and 24, at various locations (such as opposingaxial ends) liquid coolant transmission line 702 can include one or moreturns 706 that may be, in some instances, oriented substantiallyperpendicular to the axial direction (i.e., the orientation of first andsecond projecting electrodes 102) of one or more energy storage devices100 between axially oriented sections of liquid coolant transmissionline 702. Turns 706 can be contained within elongated sleeve housing 20,or may be located outside of elongated sleeve housing 20. For example,as shown in FIG. 23, elongated sleeve housing 20 can include apertures708 through which liquid coolant transmission line 702 can pass. Uponpassing through apertures 708, liquid coolant transmission line 702 cantemporarily change orientation outside energy storage device assembly 10at turns 706 and/or be connected to other components of cooling system700 discussed herein. Turns 706 may be in the form of, e.g., a singlesection of liquid coolant transmission line 702 which has been bent,shaped, or otherwise formed into a turn, or a group of several smallerconduits with elbow bends or transition adapters positioned therebetweento form the shape of turn 706. Turns 706 of liquid coolant transmissionline 702 can also be positioned within elongated sleeve housing 20 andcan extend substantially perpendicular to the axial orientation ofenergy storage device 100. In this arrangement, a portion of liquidcoolant transmission line 702 can be adjacent to and/or extend acrosstwo or more surfaces of the same energy storage device 100. Embodimentsof the present disclosure in which portions of liquid coolanttransmission line 702 directly contact one or more energy storagedevices 100, without intervening materials between each component todirectly absorb heat from energy storage devices 100, are alsocontemplated. In addition, as shown in FIG. 24, it is understood thatone or more liquid coolant transmission lines 702 can have asubstantially helical, sinusoidal, corrugated partially curved, or othertype of geometry while being positioned adjacent to one or morecorresponding energy storage devices 100. As is also shown in FIG. 23,liquid coolant transmission lines 702 can be embedded within and/or forma part of thermally conductive, electrically insulative material 704.That is, liquid coolant transmission lines 702 may be defined ascavities extending through thermally conductive, electrically insulativematerial 704, which may be formed, e.g., by the use of a mold, or bymachining a block of material. In FIG. 25, an arrangement with bends 706positioned outside of elongated sleeve housing 20 is shown. In additionor alternatively, liquid coolant transmission line 702 and/or bends 706can be contained entirely within elongated sleeve housing 20 where gapsbetween energy storage devices 100 are sufficiently sized to allowliquid coolant transmission lines 20 to pass therethrough.

Turning to FIG. 26, other components of cooling system 700 according toembodiments of the present disclosure are shown. Energy storage deviceassembly 10 and/or cooling system 700 can include a heat exchanger 710in fluid communication with liquid coolant transmission line 702. Heatexchanger 710 can supply coolant to and/or circulate coolant throughenergy storage device assembly 10. The supplied and/or circulatedcoolant from heat exchanger 710 can continuously absorb heat from energystorage devices 100 and/or other components of energy storage deviceassembly 10. In one embodiment, heat exchanger 710 may take the form ofa radiator system. In this case, heat exchanger 710 can include areservoir 712 for storing a liquid coolant to be transmitted to energystorage device assembly 10 through liquid coolant transmission line 702.Reservoir 712 can be sized and shaped (e.g., a substantiallycylindrical) to hold a reserve of liquid coolant of a predeterminedamount. A portion of liquid coolant transmission line 702 can fluidlyconnect a radiator 714 to reservoir 712. Radiator 714 can further reducethe temperature of liquid coolants traveling through liquid coolanttransmission line 702. In an embodiment, liquid coolants which haveabsorbed heat from components of energy storage device assembly 10 canenter radiator 714 to be cooled before returning to reservoir 712 and/orenergy storage device assembly 10.

Liquid coolants stored in reservoir 712 can be transmitted to energystorage device assembly 10, e.g., by a pump 716 of heat exchanger 710.As an alternative, reservoir 712, pump 716, and/or other components ofheat exchanger 710 may be provided as distinct, independent componentscoupled to each other and/or energy storage device assembly 10. Pump 716can be in the form of a mechanically actuated pump, an electricallyactuated pump, or any other currently known or later developed componentfor directing liquid from a reservoir through a particular conduit orpathway. Pump 716 can relay liquid coolant from reservoir 712 intoelongated sleeve housing 20 of energy storage device assembly 10, wherethe pumped liquid coolant can absorb heat from energy storage devices100 and/or other components within energy storage device assembly 10.

Turning to FIG. 27, cooling system 700 and/or heat exchanger 710 caninclude a fan 718 adjacent to radiator 714. Fan 718 can provide anairflow to radiator 714 to reduce the temperature of coolants or othercomponents within radiator 714. Radiator 714 and fan 718 together canincrease the total amount of cooling provided by liquid coolant withinliquid coolant transmission line 702 to energy storage device assembly10.

Other mechanisms for cooling particular coolants may also be provided inaddition to or as an alternative to heat exchanger 710 in the form of aradiator system, and include components and systems such as but notlimited to: refrigeration systems with compressed or uncompressedrefrigerants, air conditioning systems, heat sinks, convective coolingsystems, evaporative cooling systems, etc.

Although embodiments of the present disclosure are described herein asincluding energy storage device assembly 10 and cooling system 700 aselements of a complete system, it is also understood that cooling system700 can be manufactured, assembled, provided, etc. separately fromenergy storage device assembly 10. In an example embodiment, energystorage device assembly 10 can be adapted to hold one or more coolingsystems 700 therein, which can be provided separately and integratedwith the existing energy storage device assembly 10. Thus, coolingsystem 700 can include a plurality of liquid coolant transmission lines702 positioned within elongated sleeve housing 20 of energy storagedevice assembly 10, along with several energy storage devices 100. Theplurality of liquid coolant transmission lines 702 can be spatiallyarranged to absorb heat from one or more energy storage devices 100 ofenergy storage device assembly 10. As discussed elsewhere herein,cooling system 700 can also include heat exchanger 710 and/or any of itscomponents, and may be modified or adapted to include other features.Cooling system 700 can also include one or more thermally-conductive,electrically-insulative materials positioned between liquid coolanttransmission lines 702 and other components to be cooled to increase therate and amount of cooling provided.

It is further understood that cooling system 700 can be combined withone or more of the alternative embodiments and/or additional features ofenergy storage device assembly 10 discussed elsewhere herein. Forexample, cooling system 700 can be used with energy storage deviceassemblies 10 which include several energy storage devices 100 withfirst and second projecting electrodes 102, 104, and bonded directlytogether in series with weld bonds 210 (FIGS. 3, 4, 5, 6, 7A, 7D). Oneor more liquid coolant transmission lines 702 of cooling system 700 canabsorb heat from one or more of energy storage devices 100, and canoptionally be bonded to a base plate 720 of elongated sleeve housing 20for additional stability and thermal communication. One or more otheroptional components of energy storage device assembly 10 discussedherein can also be coupled to a component of cooling system 700 whereapplicable.

It is further understood that cooling system 700 can be combined withenergy storage device assemblies and systems other than that describedand illustrated herein, all of which are considered within the scope ofthe invention. For example, cooling system 700 can be combined with anenergy storage device assembly without series connections between two ormore ultracapacitors, or where alternative spatial arrangements ofenergy storage devices within an assembly are used.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the disclosure.As used herein, the singular forms “a,” “an,” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises”and/or” comprising,” when used in this specification, specify thepresence of stated features, integers, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, integers, steps, operations, elements,components, and/or groups thereof.

This written description uses examples to disclose the invention,including the best mode, and to enable any person skilled in the art topractice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and may include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they have structural elementsthat do not differ from the literal language of the claims, or if theyinclude equivalent structural elements with insubstantial differencesfrom the literal language of the claims.

What is claimed is:
 1. An energy storage device assembly comprising: aplurality of energy storage devices, each energy storage device having afirst electrode and a second electrode, the plurality of energy storagedevices being connected to one another in series; and a liquid coolanttransmission line in thermal communication with at least one of theplurality of energy storage devices.
 2. The energy storage deviceassembly of claim 1, wherein each of the plurality of energy storagedevices includes a capacitor cell.
 3. The energy storage device assemblyof claim 1, wherein a portion of the liquid coolant transmission line isaligned substantially in parallel with one of the plurality of energystorage devices.
 4. The energy storage device assembly of claim 1,further comprising a heat exchanger in fluid communication with theliquid coolant transmission line.
 5. The energy storage device assemblyof claim 1, further comprising a thermally-conductive,electrically-insulative material positioned between one of the pluralityof energy storage devices and the liquid coolant transmission line. 6.The energy storage device assembly of claim 5, wherein thethermally-conductive, electrically-insulative material includes apotting material.
 7. The energy storage device assembly of claim 1,wherein a liquid coolant of the liquid coolant includes one of anantifreeze, a compressible refrigerant, and an antifreeze-watersolution.
 8. The energy storage device assembly of claim 1, furthercomprising an elongated sleeve housing enclosing the plurality of energystorage devices and the liquid coolant transmission line.
 9. The energystorage device assembly of claim 8, wherein the elongated sleeve housingfurther includes an aperture, and a section of the liquid coolanttransmission line passes through the aperture.
 10. The energy storagedevice assembly of claim 8, wherein an entirety of the liquid coolanttransmission line is enclosed within the elongated sleeve housing. 11.The energy storage device assembly of claim 8, wherein the elongatedsleeve housing and the liquid coolant transmission line are coupled toeach other through a weld.
 12. The energy storage device of claim 1,wherein a first portion of the liquid coolant transmission line extendssubstantially across a length of at least two of the plurality of energystorage devices.
 13. The energy storage device of claim 12, wherein asecond portion of the liquid coolant transmission line further extendssubstantially across a width of at least one of the plurality of energystorage devices.
 14. The energy storage device of claim 1, wherein theliquid coolant transmission line is adjacent to at least two surfaces ofone of the plurality of energy storage devices.
 15. A cooling system foran energy storage device assembly, the cooling system comprising: aplurality of liquid coolant transmission lines positioned within anelongated sleeve housing for enclosing a plurality of energy storagedevices therein, the plurality of liquid coolant transmission linesbeing configured to absorb heat from the plurality of energy storagedevices.
 16. The cooling system of claim 15, further comprising a heatexchanger in fluid communication with one of the plurality of liquidcoolant transmission lines.
 17. The cooling system of claim 15, furthercomprising a liquid coolant within one of the plurality of liquidcoolant transmission lines, wherein the liquid coolant includes one ofan antifreeze, a compressible refrigerant, and an antifreeze-watersolution.
 18. The cooling system of claim 15, wherein at least one ofthe plurality of liquid coolant transmission lines is coupled to theelongated sleeve housing through a weld.
 19. The cooling system of claim15, wherein at least one of the plurality of liquid coolant transmissionlines extends at least partially outside the elongated sleeve housing.20. The cooling system of claim 15, further comprising athermally-conductive, electrically-insulative material contacting atleast one of the plurality of liquid coolant transmission lines.
 21. Thecooling system of claim 15, wherein a first portion of at least one ofthe plurality of liquid coolant transmission lines extends substantiallyacross a length of one of the plurality of energy storage devices, and asecond portion of the at least one of the plurality of liquid collanttransmission lines extends substantially across a width of one of theplurality of energy storage devices.
 22. The cooling system of claim 15,wherein at least one of the plurality of liquid coolant transmissionlines is embedded within the elongated sleeve housing.
 23. The coolingsystem of claim 15, wherein at least one of the plurality of liquidcoolant transmission lines is oriented substantially in parallel withone of the plurality of energy storage devices.
 24. The cooling systemof claim 15, wherein at least one of the plurality of liquid coolanttransmission lines absorbs heat from a plurality of energy storagedevices within the elongated sleeve housing.
 25. An energy storagedevice assembly comprising: a plurality of energy storage devices, eachenergy storage device having a first projecting electrode and a secondprojecting electrode; a weld directly bonding adjacent first and secondprojecting electrodes of adjacent energy storage devices to one anotherin series; and a liquid coolant transmission line in thermalcommunication with one of the plurality of energy storage devices, theliquid coolant transmission line extending substantially across thelength of at least two adjacent energy storage devices bonded to oneanother in series.
 26. The energy storage device of claim 25, furthercomprising an elongated sleeve housing enclosing the plurality of energystorage device, the elongated sleeve housing including a base plate,wherein the liquid coolant transmission line is welded to the base plateof the elongated sleeve housing.